Volume based gradient index lens by additive manufacturing

ABSTRACT

Techniques are described for forming a gradient index (GRIN) lens for propagating an electromagnetic wave comprising receiving, by a manufacturing device having one or more processors, a model comprising data specifying a plurality of layers, wherein at least one layer of the plurality of layers comprises an arrangement of one or more volume elements comprising a first dielectric material and a second dielectric material, wherein the at least one layer of the plurality of layers has a dielectric profile that is made up of a plurality of different effective dielectric constants of the volume elements in the layer, and generating, with the manufacturing device by an additive manufacturing process, the GRIN lens based on the model.

TECHNICAL FIELD

The disclosure relates to manufacturing three-dimensional (3D)structures. In particular the present disclosure relates to afabrication process for 3D optical structures.

BACKGROUND

Available radio-frequency spectra are frequently limited byjurisdictional regulations and standards. The increasing demand forbandwidth (i.e., increased data throughput) leads to the emergence of anumber of wireless point-to-point technologies that offer fiber datarates and can support dense deployment architectures. Millimeter wavecommunication systems can be used for this function, providingoperational benefits of short links, high data rates, low cost, highdensity, high security, and low transmission power.

These advantages make millimeter wave communication systems beneficialfor sending various waves in the radio-frequency spectrum. Coaxialcables are available for carrying such millimeter waves, though thecables are currently very expensive to incorporate in a millimeter wavecommunication system.

Manufacturing techniques for fabricating millimeter wave or opticaldevices and other structures include bulk machining techniques, such asgrinding lenses; precision molding to create aspheric surfaces; andplanar technological methods to produce thin film devices. Theseprocesses generally produce components which require assembly into asystem. Examples of manufactured millimeter wave or optical devicesinclude physical gradient-index (GRIN) lenses which may take the form ofconventional biconvex lenses.

Known fabrication methods for creating structures such as GRIN lensesfor radio frequency and acoustic systems may require energy-consumptiveprocessing, and may be time-consuming. GRIN lenses have been made usingseveral techniques, including neutron irradiation, chemical vapordeposition, partial polymerization, ion exchange, and ion stuffing.

SUMMARY

In general, the disclosure relates to lenses, and techniques for formingthe lenses. For example, the disclosure describes the formation ofgradient-index (GRIN) lenses for use by various radio-frequency (RF)frequencies. For example, in accordance with the techniques of thisdisclosure a GRIN lens may be formed by an additive manufacturingprocess, such as by being printed with a 3D printer, where the surfacesof the lens can be flat, curved or stepped. The material forming thelens can be printed in a pattern with a controlled amount ofsub-wavelength voids to control a local density, effective localdielectric constant, or effective local relative permittivity, and localindex of refraction. These local parameters can be continuously variedthroughout the volume of the lens to produce a lens with independentlycontrolled optical performance and physical shape, as printed by a 3Dprinter.

In one example of a method of forming a gradient index (GRIN) lens forpropagating an electromagnetic wave, the method comprising receiving, bya manufacturing device having one or more processors, a model comprisingdata specifying a plurality of layers, wherein at least one layer of theplurality of layers comprises an arrangement of one or more volumeelements comprising a first dielectric material and a second dielectricmaterial, wherein the at least one layer of the plurality of layers hasa dielectric profile that is made up of a plurality of differenteffective dielectric constants of the volume elements in the layer, andgenerating, with the manufacturing device by an additive manufacturingprocess, the GRIN lens based on the model.

In another example, a gradient index (GRIN) lens for propagating anelectromagnetic wave, the lens comprising a plurality of layersadditively formed to comprise a plurality of volume elements, wherein atleast one layer of the plurality of layers comprises an arrangement ofthe one or more volume elements comprises a first dielectric materialand a second dielectric material, wherein the volume elements are formedby an additive manufacturing process, wherein the at least one layer ofthe plurality of layers has a dielectric profile that is made up of aplurality of different effective dielectric constants of the volumeelements in the layer, and wherein each of the local effectivedielectric constants is a function of a volumetric ratio of the firstdielectric material to the second dielectric material in the respectivevolume elements, a dielectric constant of the first dielectric material,and a dielectric constant of the second dielectric material.

The details of one or more examples of the disclosure are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the disclosure will be apparent from thedescription and drawings, and from the claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a block diagram illustrating an example of a three-dimensional(3D) gradient index (GRIN) lens generation environment.

FIG. 2 is a block diagram illustrating an example of a computing devicethat operates in accordance with the techniques described herein.

FIGS. 3A-3B are conceptual diagrams illustrating an example of a 3D GRINlens focusing environment.

FIG. 4 is a diagram illustrating an example of a conceptualthree-dimensional unit cell with a respective volume of a firstdielectric material and a second dielectric material.

FIG. 5 is a diagram illustrating another example of a conceptualthree-dimensional unit cell with a respective volume of a firstdielectric material and a second dielectric material.

FIG. 6 is a diagram illustrating an example of an array of conceptualthree-dimensional unit cells with a volume based on the respectivevolumes of each three-dimensional unit cell in the array ofthree-dimensional unit cells.

FIG. 7 is a diagram illustrating an example of an array of digitalthree-dimensional voxels structured in a spoke design.

FIG. 8 is a diagram illustrating another example of an array of digitalthree-dimensional voxels structured in a ring design.

FIGS. 9A-9B are diagrams illustrating examples of an array of digitalthree-dimensional voxels structured in a combination of the spoke designand the ring design to form a spoke and ring design and a ring and spokedesign.

FIG. 10 is a diagram illustrating an example of an array of physicalthree-dimensional voxels structured in a spoke and ring design.

FIG. 11 is a diagram illustrating an example of an array of physicalthree-dimensional voxels structured in a ring and spoke design.

FIG. 12 is a graph illustrating an example of the density of a firstdielectric material according to the radius of a 3D GRIN lens.

FIGS. 13A-13B are graphs illustrating an example of the measured gainpatterns without a GRIN lens and with a GRINS lens as described in FIGS.10-11.

FIG. 14 is a conceptual diagram illustrating an example of the focusingeffect of a first dielectric material with a single dielectric constantwith a structure of a biconvex lens.

FIG. 15 is a conceptual diagram illustrating an example of a steppedGRIN lens including two or more dielectric materials with a steppeddielectric profile and focusing effect similar to a biconvex GRIN lens.

FIG. 16 is a conceptual diagram illustrating an example of the focusingeffect of two or more dielectric materials forming a stepped dielectricprofile according to one or more of the techniques disclosed herein.

FIG. 17 is a conceptual diagram illustrating an example of the focusingeffect of two or more dielectric materials forming a stepped dielectricprofile according to one or more of the techniques disclosed herein.

FIG. 18 illustrates an example of a non-woven structure with two or moredielectric materials according to one or more of the techniquesdisclosed herein.

FIG. 19 illustrates another example of a non-woven structure with two ormore dielectric materials according to one or more of the techniquesdisclosed herein.

FIG. 20 is a flowchart illustrating an example process of an additivemanufacturing device generating a 3D GRIN lens with two or moredielectric materials according to the techniques disclosed herein.

DETAILED DESCRIPTION

The present disclosure describes techniques for creating, customizing,and generating gradient-index (GRIN) lenses that correspond to adifferent GRIN lens structure while maintaining a similar dielectricconstant profile. For example, techniques are described for creating adigital GRIN lens representation within a virtual environment, capturinginformation therefrom, and generating, through additive manufacturing,physical GRIN lenses that correspond to the digital GRIN lensrepresentation. Further, at least some aspects of the present disclosureare directed to techniques for managing multiple aspects of GRIN lenses,such as dielectric constant, shape, or the like. The term “dielectricconstant” as used herein refers to the relative permittivity of thephysical GRIN lens, and the terms “dielectric constant” and “relativepermittivity” may be used interchangeably.

In general, GRIN lenses can include physical GRIN lenses and digitalGRIN lens representations. Physical GRIN lenses generally refer tophysical objects with a general boundary, weight, and shape used tofocus light (including infrared and ultraviolet) or otherelectromagnetic signals, such as extremely high frequency (EHF) signalswith frequencies from 30 to 300 gigahertz (GHz), for example. PhysicalGRIN lenses can include the resulting objects after being built, molded,or produced, for example by a computer numerical control (CNC) machine,a 3D printer, or the like, based on a digital GRIN lens representation.

Using the techniques of the disclosure, a GRIN lens may be printed withan additive manufacturing device, such as a 3D printer, for use at RFfrequencies, where the surfaces of the lens can be flat, curved orstepped, and the material can be printed in a pattern with a controlledamount of sub-wavelength voids to control the local density, effectivelocal dielectric constant, and local index of refraction. These localparameters can be continuously varied throughout the volume of the lensto produce a lens with independently controlled optical performance andphysical shape, as printed by an additive manufacturing device. Controlof the refractive index in dimensions x, y and z, enables uniqueconstructions that can provide a lens function while also providingcontrol of numerous aberrations, including spherical and chromaticaberrations, while also providing design freedom for the lens surfaces.

Moreover, using one or more techniques described in this disclosure,lenses having a wide variety of shapes or contours may be created toconform to any desired dielectric profile, such as a dielectric profileof a biconvex GRIN lens. Physical GRIN lenses can have various shapesand sizes. As one example, a physical GRIN lens may have a 50 millimeter(mm) diameter and 7.8 mm thickness. In some cases, physical GRIN lensesmay have known shapes and/or dimensions that conform to standards. Forexample, a lens may be formed to take a conventional lens shape such asa convex and/or concave lens, or may be formed in other known shapes,which may not be limited to geometric shapes, such as squares,rectangles, circles, or the like. In some examples, physical GRIN lensesmay have a variety of contours, continuous or otherwise, such as curvedcontours and flat contours. Moreover, in one example, a dimension of alens such as diameter may be smaller than a specified number ofwavelengths, such as 10 wavelengths. In other cases, using one or moretechniques described in this disclosure, physical GRIN lenses may havenon-standardized shapes, and/or irregular dimensions.

The term “digital GRIN lens representation” is used herein to refer todigital objects with information and/or virtual boundaries, such asnumber of voxels per layer, and the effective dielectric constant ofeach voxel necessary to achieve a dielectric profile based on theplurality of effective dielectric constants. Digital GRIN lensrepresentations can be generated using digital inputs. Digital inputscan include, for example, keyboards, touch screens, mice, or the like.

In some cases, digital GRIN lens representations are created in avirtual space and may be representative of physical GRIN lenses. Virtualspace may refer to a computer aided design (CAD) environment, forexample, that allows a user to manually create or automatically generatea digital GRIN lens representation having desired parameters, such asshape, size, and dielectric profile. The virtual space may be referredto as a modeling space, workspace, or the like.

FIG. 1 is a block diagram illustrating an example of a GRIN lensgeneration environment 10. In the example of FIG. 1, GRIN lensgeneration environment 10 includes a computing device 14 to causeadditive manufacturing (AM) device 24 to generate one or more physicalGRIN lenses from model 22 of a digital GRIN lens representation. Asdescribed herein, computing device 14 provides an execution environmentfor one or more software applications that, as described, canefficiently generate and edit GRIN lens content for a large number ofdigital GRIN lens representations. In this example, a digital GRIN lensrepresentation may be previously stored by computing device 14. Asdescribed, computing device 14 and the software applications executingthereon may perform a variety of fabrication-related operations,including automated generation of model 22 of a digital GRIN lensrepresentation, and automatic fabrication of physical GRIN lensesrepresentative of model 22 using additive manufacturing (AM) device 24.

In the example implementation, computing device 14 includes, among othercomponents, presentation device 20 and keyboard 18. In addition,although not shown in FIG. 1, computing device 14 may include one ormore processors, microprocessors, internal memory and/or data storageand other electronic circuitry for executing software or firmware toprovide the functionality described herein.

Presentation device 20 may include, for example, an electronicallyaddressable display, such as a liquid crystal display (LCD) or othertype of display device for use with computing device 14. In someimplementations, computing device 14 generates the content to display onpresentation device 20 for the digital GRIN lens representation in avariety of views, for example, a top view, a bottom view, an explodedview, a layer by layer view, a voxel by voxel view, or the like.Computing device 14 may, in some cases, communicate display informationfor presentation by other devices, such as a tablet computer, aprojector, or other external device.

Keyboard 18 may include, for example, a physical user interface, such askeys or other type of physical user interface device for use withcomputing device 14. Computing device 14 may, in some cases, generatemodel 22 based on the information received from a user (not shown) bykeyboard 18.

As described herein, computing device 14, and the software executingthereon, provide a platform for creating and manipulating digital GRINlens representations representative of physical GRIN lenses. Forexample, in general, computing device 14 is configured to create and/orgenerate model 22 of a digital GRIN lens representation. In someexamples, model 22 is created by a user (not shown). In other examples,model 22 is stored in a database, as described in FIG. 2. Computingdevice 14 may provide AM device 24 data indicative of model 22 to allowAM device 24 to fabricate at least one physical GRIN lens (not shown)based on model 22.

AM device 24 is a device capable of making a three-dimensional physicalobject from a digital model. In one example, AM device 24 is a 3Dprinter that can print using an additive process, where successivelayers of material are laid down in different shapes and/or line widths.This layering of material is different than traditional methods ofmachining, which may rely on the removal of material by cutting ordrilling, also known as subtractive processes. In some examples, AMdevice 24 may use a two-photon photopolymerization process to createthree-dimensional (3D) structure with micro- or nano-scale resolutions.Examples of a two-photon photopolymerization process are described inU.S. Pat. No. 6,855,478, issued Feb. 15, 2005, the entire contents ofwhich are incorporated by reference herein.

As further described below, computing device 14 may implement techniquesfor automated generation of model 22 of digital GRIN lensrepresentations, and extraction of information, content or othercharacteristics associated with each of the digital GRIN lensrepresentations. For example, computing device 14 may allow a userfine-grained control over techniques used by computing device 14 togenerate one or more models of digital GRIN lens representation, such asmodel 22. In accordance with the techniques described herein, computingdevice 14 may implement techniques for automatic generation of model 22of a digital GRIN lens representation by processing a plurality oflayers having a plurality of effective dielectric constants based on anoverall dielectric constant profile. Computing device 14 may providealternate shapes and/or sizes of model 22 based on the arrangement ofthe plurality of effective dielectric constants in the plurality oflayers corresponding to the overall dielectric profile.

In some examples, the overall dielectric profile of the model 22 mayinclude the plurality of effective dielectric constants defined by aplurality of voxels, and each voxel of model 22 may include a volume ofa first dielectric material associated with a first dielectric constantand a volume of a second dielectric material associated with a seconddielectric constant. In other examples, the plurality of voxels of model22 may include an arrangement of one or more volume elements having anarrangement of one or more lines formed by the additive manufacturingprocess. In other examples, the overall dielectric profile may includethe plurality of effective dielectric constants defined by a pluralityof layers, where each layer may include a volume of a first dielectricmaterial associated with a first dielectric constant and a volume of asecond material associated with a second dielectric constant. In someexamples, the first dielectric material may include a photo-reactiveresin associated, e.g., having a relative dielectric constant of 2.8,and the second dielectric material may include air associated with arelative dielectric constant of about 1. The absolute dielectricconstant of air is close the dielectric constant of a vacuum, which isroughly 8.8541878176×10⁻¹² F/m. A relative dielectric constant of 2.8represents the absolute dielectric constant is 2.8 times greater thanthe dielectric constant of a vacuum.

A voxel may be a volume element and may represent a value on a regulargrid in three-dimensional space. In some examples, voxels may also be anarray of elements of volume that constitute a notional three-dimensionalspace. That is, each voxel in a plurality of voxels may form an array ofdiscrete volume elements into which a representation of athree-dimensional object may be divided. In some examples, a voxel maybe a volume element, where the volume element includes a particularvolume (amount) of one or more dielectric materials. For example, insome cases a voxel may be comprised entirely of a volume of a firstdielectric material, providing an effective dielectric constant for thatvoxel that is equal to the dielectric constant of the first dielectricmaterial. In other examples, a voxel may comprise the combination of avolume of first dielectric material and a second dielectric material,whereby the effective dielectric constant for the voxel is a functioneffective of the respective dielectric constants of the one or moredielectric materials.

A layer may be a plurality of volume elements and represents a pluralityof values on a regular grid in three-dimensional space. In someexamples, a layer may have a plurality of voxels, such that theplurality of voxels may comprise a plurality of volumes between one ormore dielectric materials. In other examples, a layer may have aplurality of effective dielectric constants defined by the plurality ofvolumes of the one or more effective dielectric constants.

In accordance with the techniques of this disclosure, based on model 22,AM device 24 can vary the ratios of the one or more dielectricmaterials, such as the ratio of the first dielectric material to thesecond dielectric material, can be varied on a voxel-by-voxel orlayer-by-layer basis. In one example of the ratio between the first andsecond dielectric materials, the higher the ratio, the closer thedensity and effective dielectric constant of the unit cell (e.g., voxel)approaches the dielectric constant of the first dielectric material(e.g., bulk 3D print material). The lower this ratio, the closer theeffective dielectric constant of the unit cell approaches the dielectricconstant of the second dielectric material (e.g., free space, air, orwhatever medium in which the physical GRIN lens structure is immersed).

In one example implementation, a voxel may be comprised entirely of avolume of a first dielectric material, such as thermoplastic resin orphoto-reactive resin with an associated dielectric constant of 2.8. Inthis example, the effective dielectric constant for the voxel is 2.8because the voxel is comprised entirely of the first dielectric materialwith an associated dielectric constant of 2.8. In another example, avoxel may be comprised of respective volumes of multiple (e.g., two ormore) different dielectric materials, such as a first dielectricmaterial (e.g., thermoplastic resin, photo-reactive resin) with anassociated first dielectric constant of 2.8, and a second dielectricmaterial (e.g., air) with an associated second dielectric constant of 1.In some examples, the dielectric materials may be solids, liquids, orgases. In other examples, the effective dielectric constant for thevoxel is effectively a function of the volumes between the firstdielectric material and the second dielectric material and theirrespective dielectric constants.

In another example implementation, a digital GRIN lens representationmodeling application executing on computing device 14 may separate model22 into a plurality of layers representative of a plurality of differenteffective dielectric constants in a dielectric profile. In some exampleimplementations, for each of the plurality of effective dielectricconstants, computer device 14 may generate one or more of the layerswith one or more dielectric materials corresponding to the effectivedielectric constants of each layer. According to this layer approach,dielectric constants from the different layers are detected, and used toultimately define the volume of one or more dielectric materials in eachlayer for an individual physical GRIN lens. As a result, each of theplurality of digital GRIN lens representations generated by digital GRINlens representation modeling application 30 may be represented by aplurality of layers. In some examples, model 22 may represent thedifferent effective dielectric constants of the layers by a differentcolor. In other examples, the plurality of players of model 22 mayinclude an arrangement of one or more volume elements having anarrangement of one or more lines formed by the additive manufacturingprocess.

In some example implementations, GRIN lenses formed according to thetechniques of this disclosure may be used to provide a focusingfunction. In other example implementations, GRIN lenses formed accordingto the techniques of this disclosure may be used to createanti-reflective coatings and/or layers. In yet other exampleimplementations, computing device 14 provides functionality by which auser is able to export the digital GRIN lens representation to othersystems, such as cloud-based repositories (e.g., cloud server) or othercomputing devices (e.g., computer system or mobile device) (not shown).

In the example of FIG. 1, computing device 14 is illustrated forpurposes of example as a desktop computer. However, in other examples,computing device 14 may be a tablet computer, a personal digitalassistant (PDA), a smartphone, a laptop computer, or any other type ofcomputing or non-computing computing device suitable for performing thetechniques described herein.

FIG. 2 is a block diagram illustrating an example of a computing devicethat operates in accordance with the techniques described herein. Forpurposes of example, computing device 14 of FIG. 2 will be describedwith respect to computing device 14 of FIG. 1

In this example, computing device 14 includes various hardwarecomponents that provide core functionality for operation of the device.For example, computing device 14 includes one or more programmableprocessors 38 configured to operate according to executable instructions(i.e., program code), typically stored in a computer-readable medium ordata storage 36 such as static, random-access memory (SRAM) device orFlash memory device. Input/Output (I/O) 40 may include one or moredevices, such as keyboard 18 as described in FIG. 1, mouse, trackball,or presentation device 20 as described in FIG. 1, and provide wirelesscommunication with other devices, such as a cloud server, a computersystem, or AM device 24 as described in FIG. 1, via a wireless or wiredcommunication interface as described in FIG. 1, such as but not limitedto high-frequency radio frequency (RF) signals or universal serial bus(USB) connections. In another example, computing device 14 of FIG. 1includes AM device management module 44 and GRIN lens data 42. Computingdevice 14 may include additional discrete digital logic or analogcircuitry not shown in FIG. 2.

GRIN lens data 42 may be a database of GRIN lens models, for example,including model 22 as described in FIG. 1. In some examples, modelingapplication 30 may store GRIN lens models in GRIN lens data 42. In otherexamples, modeling application 30 may retrieve GRIN lens models fromGRIN lens data 42.

AM device management 44 may control AM device 24 as described in FIG. 1.In some examples, modeling application 30 may retrieve a GRIN lens modelfrom GRIN lens data 42 and output the GRIN lens model to AM device 24.In other examples, AM device management 44 may control AM device 24using model 22 from modeling application 30, which may have retrievedmodel 22 from GRIN lens data 42 or generated model 22 from the input ofa user.

In general, operating system 34 executes on processor 38 and provides anoperating environment for one or more user applications, includingmodeling application 30. User applications may, for example, compriseexecutable program code stored in computer-readable storage device(e.g., data storage 36) for execution by processor 38. As otherexamples, the user applications may comprise firmware or, in someexamples, may be implemented in discrete logic.

In operation, computing device 14 receives user input from a userthrough I/O 40, such as keyboard 18 as described in FIG. 1, andprocesses the user input in accordance with the techniques describedherein. For example, modeling application 30 may create model 22 asdescribed in FIG. 1, in a virtual space based on a plurality of layers,and each layer comprised of an array of voxels with a plurality ofvolumes of one or more dielectric materials. As another example,computing device 14 may receive digital GRIN lens representation datafrom internal sources, such as GRIN lens data 42, or external sources,such as a cloud server, a computer system, or a mobile device via I/O40. In general, computing device 14 stores the digital GRIN lensrepresentation data in GRIN lens data 42 for access and processing bymodeling application 30 and/or other user applications.

As shown in FIG. 2, modeling application 30 may invoke kernel functionsof operating system 34 to output data to for presenting information to auser of computing device, such as computing device 14 as described inFIG. 1. As further described below, modeling application 30 may generatea graphical user interface to provide an improved electronic environmentfor generating and manipulating model 22 of corresponding digital GRINlens representations representative of physical GRIN lenses. Forexample, modeling application 30 may generate a graphical user interfaceto include a mechanism that allows a user to easily select shapes andsizes of one or more digital GRIN lens representations based on thedesired dielectric profile. In some examples, the desired dielectricprofile is selected to enable the GRIN lens to focus an electromagneticwave. In other examples, the electromagnetic wave is within a millimeterwave band.

As described in further detail below, modeling application 30 mayutilize automated GRIN lens profile techniques that separate model 22,as described in FIG. 1, into a plurality of layers. Modeling application30 can, for each of the layers, arrange a plurality of voxels accordingto a desired shape and/or size corresponding to a plurality of effectivedielectric constants of a desired dielectric profile. According to avoxel approach, each voxel may be individually defined as having one ormore dielectric materials within each of the layers of model 22. Basedon the volume of each of the one or more dielectric materials in thevoxel, each voxel has an effective dielectric constant, and the localdielectric constant at a given position within the plurality of layersmay correspond to the desired dielectric profile. In some cases,modeling application 30 may, for example, generate model 22 based on theinput of a user selecting a desired size and shape of a GRIN lens to beformed having a dielectric profile, providing the desired functionalitysuch as an imaging lens. In other cases, the imaging lens may be similarto the functionality of a solid biconvex GRIN lens. Moreover, modelingapplication 30 may output model 22 to AM device management 44 to controlAM device 24, as described in FIG. 1.

To generate model 22, modeling application 30 may create a plurality oflayers, where each layer has a plurality of effective dielectricconstants corresponding to the desired dielectric profile, providing thedesired functionality such as an imaging lens, similar to thefunctionality of a solid single dielectric constant biconvex lens. Insome examples, modeling application 30 may change the dielectricconstant of each layer by individually defining the effective dielectricconstant of each voxel in a layer by controlling the volume of the oneor more dielectric materials in each voxel. In other examples, modelingapplication 30 may change the dielectric constant of each layer bydefining each layer with a volume of two or more dielectric materials,such that the volume of two or more dielectric materials corresponds toa plurality of effective dielectric constants across each layer, and aspart of an overall dielectric profile. As a result, in this example,each of the plurality of digital GRIN lens representations generated bymodeling application 30 for a given dielectric profile, such as abiconvex lens dielectric profile, may also be represented by a pluralityof other digital GRIN lens representations with different shapes and/orsizes, and all of which correspond to the functionality of the imaginglens, such as a biconvex lens. In this manner, modeling application 30may be used to generate data for fabricating a GRIN lens having acustomized shape and size (e.g., form factor), and that also has adielectric profile that results in a lens functionality (or wavefrontmanipulation) that approximates the functionality of a conventionalbiconvex lens.

FIGS. 3A-3B illustrate an example of a three-dimensional (3D) GRIN lensfocusing environment 50. In the example of GRIN lens focusingenvironment 50 includes FIG. 3A with waveguide 52 configured to guidetransmission of electromagnetic waves 56, such as electromagnetic waveshaving a frequency of approximately 60 GHz, and FIG. 3B with 3D GRINlens 54 to focus the electromagnetic waves, such as electromagneticwaves 56 at point 58.

In the example of FIGS. 3A & 3B, waveguide 52 is a structure for guidingand radiating electromagnetic waves 56. Waveguide 52 generally confinesthe signal to travel in one dimension. Electromagnetic waves 56typically propagate in all directions as spherical waves when in openspace. When this happens, electromagnetic waves 56 lose their powerproportionally to the square of the distance traveled. Under idealconditions, when waveguide 52 confines an electromagnetic wave totraveling in only a single direction, the wave loses little to no powerwhile propagating.

In the example of FIGS. 3A & 3B, waveguide 52 is a structure with anopening (e.g., a flange) at each end of its length, the two openings,or, ports (such as port 60), being connected by a hollow portion alongthe length of the interior of the waveguide 52. Waveguide 52 can be madeof copper, brass, silver, aluminum, for example, or other metal having alow bulk resistivity. In some examples, waveguide 52 can be made ofmetal with poor conductivity characteristics, plastic, or othernon-conductive materials, if the interior walls of the waveguide 52 areplated with a low bulk resistivity metal. In addition, although notshown in FIGS. 3A and 3B, waveguide 52 may be connected to an antenna,dielectric coupling lens, or other electronic components to provide thefunctionality described herein.

In the example of FIG. 3A, 3D GRIN lens 54 may include, a GRIN lensproduced using the techniques described herein. In some examples, 3DGRIN lens 54 may have a dielectric profile or relative permittivity andfunctionality, such as for providing a similar focusing effect onelectromagnetic waves 56 as a conventional biconvex GRIN lens would, butwith a different physical structure and form factor. For example, 3DGRIN lens 54 may be flat, curved, or any contour, shape, and/or sizeavailable to additive manufacturing while still producing a similarfocusing effect as a conventional GRIN lens, such as a biconvex lens,because of the similar dielectric profile. In other examples, 3D GRINlens 54 may improve bandwidth as compared to a conventional convex lens,such as providing functionality over a greater frequency span by areduction in chromatic aberrations.

In yet other examples, 3D GRIN lens 54 may have flat contours which canbe easier to attach and mount to other physical objects. In someexamples, 3D GRIN lens 54 may be designed to pass a gas or liquidthrough one of the dielectric materials in its structure, a feature thatmay not be possible with a solid biconvex GRIN lens having a singledielectric material with a signal dielectric constant throughout thelens. In other examples, 3D GRIN lens 54 may be designed with a specificporosity to filter gas or liquid through one of the dielectric materialsin its structure, a feature that may not be possible with a solidbiconvex GRIN lens. In some examples, a size of voids within 3D GRINlens 54 may be controlled by an additive manufacturing process to meetspecific filtering requirements. In yet other examples, 3D GRIN lens 54may be used to create non-reflective coatings and/or layers. In someexamples, 3D GRIN lens 54 may enable polar selectivity based on theconstruction of the two or more dielectric materials. In other examples,3D GRIN lens 54 may be created by AM device 24 with a range of printmaterials with an associated range of dielectric constants. In someexamples, it may be beneficial to use only a single (or small number of)3D printing material, printed with a controlled density to vary thedielectric constant in a controlled manner. In some examples, thethickness of each layer of 3D GRIN lens 54 may be relatively smallcompared to the wavelength of a specific frequency. In other examples,the thickness of each layer may be smaller than a wavelength, such as athickness between 1/10 and 1/15 of a wavelength of a desired frequency.In yet other examples, the desired frequency may be 60 GHz. In someexamples, the volumetric ratio of the first dielectric material to thesecond dielectric material in the respective volume elements iscontrolled by a line width of the first dielectric material formed bythe additive manufacturing process. In other examples, 3D GRIN lens 54may have a first dielectric material of a thermoplastic resin or aphoto-reactive resin. In other examples, 3D GRIN lens 54 may have asecond dielectric material of air or at least one of a thermoplasticresin or photo-reactive resin.

In the example of FIG. 3B, electromagnetic waves 56 may includeextremely high frequency electromagnetic waves, such as electromagneticwaves having a frequency of approximately 60 GHz. In someimplementations of FIGS. 3A & 3B, waveguide 52 transmits electromagneticwaves 56 that pass through 3D GRIN lens 54 in order to focuselectromagnetic waves 56 at point 58. In other implementations of FIGS.3A & 3B, waveguide 52 receives electromagnetic waves 56 that passthrough 3D GRIN lens 54 in order to focus electromagnetic waves 56 intowaveguide 52.

In some examples, 3D GRIN lens 54 may be useful in the millimeter waveband of the electromagnetic spectrum. In some examples, 3D GRIN lens 54may be used with signals at frequencies ranging from 10 GHz to 120 GHz,for example. In other examples, 3D GRIN lens 54 may be used with signalsat frequencies ranging from 10 GHz to 300 GHz, for example. 3D GRIN lens54 could be used in a variety of systems, including, for example, lowcost cable markets, contactless measurement applications, chip-to-chipcommunications, and various other wireless point-to-point applicationsthat offer fiber data rates and can support dense deploymentarchitectures.

FIG. 4 is a diagram illustrating an example of a conceptualthree-dimensional unit cell 100 with a volume of first dielectricmaterial 102 and a volume of a second dielectric material 104. In theexample of FIG. 4, unit cell 100 includes two different dielectricmaterials 102, 104 each with their own respective volume and respectivedielectric constant. In one example, unit cell 100 may have a structuredefining a volume of dielectric material 102 (e.g., a photo-reactiveresin) having a dielectric constant of 2.8. In another example, unitcell 100 may have another structure, such as a void, with a seconddielectric material 104 defining a volume (e.g., air) having adielectric constant of 1 within the unit cell 100. The effectivedielectric constant of unit cell 100 is a function of the respectivevolumes of the two dielectric materials 102, 104. In other examples,unit cell 100 may be any shape available to AM device 24, as describedin FIG. 1, such as a box, sphere, or rectangle. In some examples, unitcell 100 may represent a voxel. In other examples, unit cell 100 mayrepresent a plurality of voxels.

In one example implementation, unit cell 100 may be laid down repeatedlyby an additive manufacturing process to fill the GRIN lens volume suchas with the voxel by voxel or layer by layer approach as described inFIG. 1. In another example implementation, if structures of unit cell100 of FIG. 4 are significantly small relative to the wavelength of thewave being manipulated, then the structure will function as a singlehomogeneous material with an effective dielectric constant between thetwo dielectric constants (e.g. air and 3D printing material), based onthe volumetric ratios of the two materials and the voxel geometry. Insome examples, the first dielectric material may be loaded with low losshigh dielectric material to further expand the range of RF opticalapplications of additive manufacturing of 3D GRIN lenses.

FIG. 5 is a diagram illustrating another example of a conceptualthree-dimensional unit cell 110 with a volume of first dielectricmaterial 112 and a volume of second dielectric material 114. In someexamples, the dielectric materials 112, 114 of FIG. 5 may be the samedielectric materials as dielectric materials 102, 104 (FIG. 4),respectively. In the example of FIG. 5, unit cell 110 includes twodifferent dielectric materials 112, 114 each with their own respectivevolume and respective dielectric constant. In one example, unit cell 110may be structured as a unit cell with a first dielectric material 112(e.g., a photo-reactive resin) having a dielectric constant of 2.8. Inanother example, unit cell 110 may include a void with a seconddielectric material 114 defining a volume having a dielectric constantof 1 within the box of dielectric material 112. The effective dielectricconstant of unit cell 110 is defined by a function of the respectivevolumes of the two dielectric materials 112, 114. In other examples,unit cell 110 may be any shape available to AM device 24, as describedin FIG. 1, such as a box, sphere, or rectangle. In another example ofFIG. 5, unit cell 110 may have more of a first dielectric material 112than a second dielectric material 114, unlike unit cell 100 of FIG. 4where the first dielectric material 102 has less volume than the seconddielectric material 104. In some examples, the effective dielectricconstant of unit cell 110 is higher than the effective dielectricconstant of unit cell 100 because unit cell 110 has a higher ratio ofdielectric constant material than unit cell 100. In some examples, unitcell 110 may represent a voxel. In other examples, unit cell 110 mayrepresent a plurality of voxels.

In one example implementation, unit cell 110 may be repeated to fill theGRIN lens volume, such as the voxel by voxel or layer by layer approachas described in FIG. 1. In another example implementation, if structuresof unit cell 110 of FIG. 5 are significantly small relative to thewavelength of the wave being manipulated, then the structure willfunction as a single homogeneous material with an effective dielectricconstant between the two dielectric constants (e.g. air and 3D printingmaterial), based on the volumetric ratios of the two dielectricmaterials and the voxel geometry. In some examples, the first dielectricmaterial may be loaded with low loss high dielectric material to furtherexpand the range of RF optical applications of additive manufacturing of3D GRIN lenses.

FIG. 6 is a diagram illustrating an example of an array of conceptualthree-dimensional unit cells with a volume based on the respectivevolumes of each three-dimensional unit cell in the array ofthree-dimensional unit cells. In some examples, dielectric materials130,132, 134, 136 of FIG. 6 may correspond to one or more of dielectricmaterials 102, 104, 112, 114 of FIGS. 4-5. In the example of FIG. 6,unit cell 120 includes two different dielectric materials, such as afirst dielectric material and a second dielectric material, each with arespective volume and respective dielectric constant. In one example,array of unit cells 120 may have a structure, such as a box, and avolume defined by a first dielectric material 130, 134 (e.g., aphoto-reactive resin) having a dielectric constant of 2.8. In anotherexample, may have a structure, such as a void, and a volume defined by asecond dielectric material 132, 136 having a dielectric constant of 1.The effective dielectric constant of array of unit cells 120 is definedby a function of the respective volumes of the dielectric materials130,132, 134, 136. In other examples, array of unit cells 120 may be anyshape available to AM device 24, as described in FIG. 1, such as asphere, rectangle, cylinder, or tetrahedron. In another example of FIG.6, array of unit cells 120 may have one unit cell with more volume of afirst dielectric material 130 than a volume of a second dielectricmaterial 132, such as unit cell 110 as described in FIG. 5. In someexamples, the effective dielectric constant of unit cell 110, asdescribed in FIG. 5, is higher than the effective dielectric constant ofunit cell 100 because unit cell 110 has a higher ratio of the higherdielectric constant material than unit cell 100. In some examples, arrayof unit cells 120 may comprise an array of voxels. In other examples,array of unit cells 120 may have an effective dielectric constant as afunction of the respective volumes of the one or more dielectricmaterials in the array of unit cells.

In one example implementation, array of unit cells 120 may be laid downrepeatedly by additive manufacturing to fill the GRIN lens volume, suchas the voxel by voxel or layer by layer approach as described in FIG. 1.In another example implementation, if the unit cells in the array ofunit cells 120 of FIG. 6 are significantly small relative to thewavelength of the wave being manipulated, then the structure mayfunction as a single homogeneous material with an effective dielectricconstant between the two dielectric constants (e.g. air and 3D printingmaterial), based on the volumetric ratios of the two dielectricmaterials and the voxel geometry. In some examples, the first dielectricmaterial may be loaded with low loss high dielectric material to furtherexpand the range of RF optical applications of additive manufacturing of3D GRIN lenses. In other examples, array of unit cells 120 may bereferred to as a grid pattern. In some examples, the volumetric ratio ofthe first dielectric material to the second dielectric material in therespective volume elements is controlled by a line width of the firstdielectric material formed by the additive manufacturing process.

FIG. 7 is a diagram illustrating an example of an array of digitalthree-dimensional voxels structured in spoke design 200. In the exampleof FIG. 7, the spoke design 200 includes spoke rings, voids, and acircle, such as spoke rings 202-212, circle 214, and voids 222-224.Spoke rings 202-212 may consist of a first dielectric material (e.g.,photo-reactive resin) with an associated dielectric constant of 2.8.Voids 222-224 may be similar to spoke rings 202-214, such that voids222-224 are comprised of a second dielectric material (e.g., air) withan associated dielectric constant of 1.

In one example implementation of spoke design 200, spoke ring 202 hasthe lowest ratio of first dielectric material (e.g., photo-reactiveresin) to void 222 comprised of second dielectric material (e.g., air).In other examples, each subsequent spoke ring, such as spoke rings204-212, has a higher ratio of the first dielectric material to the voidcomprised of a second dielectric material. That is, in one example, anouter spoke ring 212 has the highest ratio of first dielectric materialto the second dielectric material. Moreover, in one example of FIG. 7,circle 214 may be formed of one solid dielectric material, such as thefirst dielectric material.

In some examples of FIG. 7, spoke rings 202-212, circle 214, and voids222-224 each may have a plurality of effective dielectric constantscorresponding to an overall dielectric profile for spoke design 200. Inone example, spoke rings 202-212 and circle 214 have an effectivedielectric constant based on the volume of the first dielectricmaterial, and voids 222-224 may have an effective dielectric constantbased on the second dielectric material. In some examples, spoke rings202-212 may have an effective constant based on the volumes of one ormore dielectric materials. In other examples, circle 214 may have aneffective dielectric constant based on one or more dielectric materials.In yet other examples, voids 222-224 may have an effective dielectricconstant based on one or more dielectric materials. In some examples ofspoke design 200 of FIG. 7, the plurality of effective dielectricconstants for the spoke rings, circle, and voids may comprise an overalldielectric profile similar to a dielectric profile of GRIN lens, such asa biconvex lens. In some examples implementations, spoke design 200 mayhave one or more layers with an overall diameter as a function of thewavelength of the waves being focused. For example, spoke design 200 mayhave one or more layers with a diameter of 10 wavelengths, such as 50 mmequivalent to 10 wavelengths at 60 GHz. In some examples, spoke design200 may be referred to as a spoke pattern. In other examples, thevolumetric ratio of the first dielectric material to the seconddielectric material in the respective volume elements is controlled by aline width of the first dielectric material formed by the additivemanufacturing process.

FIG. 8 is a diagram illustrating another example of an array of digitalthree-dimensional voxels structured in ring design 250. In the exampleof FIG. 8, the ring design includes rings 252-258, circle 260, and voids262-264. Rings 252-258 may consist of a different ratio of dielectricmaterials (e.g., photo-reactive resin and air) structured in a ringdesign. Voids 262-264 may be similar to rings 252-258, such that voids262-264 may consist of a different ratio of dielectric materials in aring design (not shown). For example, ring 252 has the lowest ratio offirst dielectric material (e.g., photo-reactive resin) and the seconddielectric material (e.g., air) because ring 252 has the greatestdiameter and is adjacent to void 262 with the largest volume of seconddielectric material (e.g., air). In other examples, each subsequentring, such as rings 254-258, has a higher ratio of the first dielectricmaterial to the second dielectric material. That is, in one example,ring 252 has the highest ratio of first dielectric material to thesecond dielectric material. Moreover, in one example of FIG. 8, circle260 has one dielectric material, such as the first dielectric material(e.g., photo-reactive resin), and voids 262-264 may have one dielectricmaterial, such as the second dielectric material (e.g., air).

In some examples of FIG. 8, the first dielectric material has adielectric constant of 2.8 and the second dielectric material has adielectric constant of 1. Rings 252-258, circle 260, and voids 262-264each have an effective dielectric constant as part of a dielectricprofile for ring design 250. In one example, rings 252-258 may have aneffective dielectric constant based on the volumes of the first andsecond dielectric materials, circle 260 may have an effective dielectricconstant based on the first dielectric material, and voids 262-264 mayhave an effective dielectric constant based on the second dielectricmaterial. In some examples, rings 252-258 may have an effective constantbased on the volumes of two or more dielectric materials. In otherexamples, circle 260 may have an effective dielectric constant based onone or more dielectric materials. In yet other examples, voids 262-264may have an effective dielectric constant based on one or moredielectric materials. In some examples of ring design 250 of FIG. 8, theeffective dielectric constants for the rings, circle, and voids maytogether form an overall dielectric profile similar to a GRIN lens, suchas a biconvex lens. In some examples, ring design 250 may be referred toas a ring pattern. In other examples, the volumetric ratio of the firstdielectric material to the second dielectric material in the respectivevolume elements is controlled by a line width of the first dielectricmaterial formed by the additive manufacturing process.

FIGS. 9A-9B are diagrams illustrating examples of an array of digitalthree-dimensional voxels structured in a combination of spoke design 200and ring design 250 to form spoke and ring design 300A and ring andspoke design 300B. In some examples of FIGS. 9A & 9B, some referencenumerals may be described in accordance with FIGS. 7-8. In some examplesof spoke and ring design 300A and the ring and spoke design 300B, theGRIN lens may be constructed with an alternating layer of ring layersand spoke layers to reduce its sensitivity to the polarization of an EMwave. In other examples of FIGS. 9A & 9B, designs 300A, 300B mayalternate 15 spoke layers with 15 ring layers. In yet other examples,designs 300A, 300B may have a plurality of spoke layers alternating withring layers. In some examples, the thickness of each layer may be smallrelative to the wavelength. In the spoke and ring design 300A and thering and spoke design 300B the thickness of each layer may be between1/10 to 1/15 of a wavelength thick at 60 GHz. In free space a wavelengthat 60 GHz is 5 mm, but in a material with a relative dielectric constantof 2.8, the wavelength is 5 mm/squareroot (2.8). In some examples,designs 300A, 300B may interleave 15 spoke layers with 15 ring layers toachieve a thickness of 7.8 mm.

In the example of FIG. 9A, the array of three-dimensional voxels 300Aincludes ring layers, spoke layers, voids, and a circle, such as ringlayer 306A, spoke layer 304A, void 308A, and circle 302A. Ring layer306A, spoke 304A, and void 308A may consist of a different volume of oneor more dielectric materials (e.g., photo-reactive resin and air)structured in the spoke and ring design. For example, ring layer 306Ahas the lowest ratio of first dielectric material (e.g., photo-reactiveresin) to second dielectric material (e.g., air), as void 308A has thelargest volume at the edge of spoke and ring design 300. In otherexamples, each subsequent ring has a higher ratio of the firstdielectric material to the second dielectric material because the volumeof in the voids gets smaller towards circle 302A. That is, in oneexample, the ring closest to the center has the highest ratio of firstdielectric material to the second dielectric material. Moreover, in oneexample of FIG. 9A, circle 302A has one dielectric material, such as thefirst dielectric material (e.g., photo-reactive resin).

In some examples of FIG. 9A, the first dielectric material has adielectric constant of 2.8 and the second dielectric material has adielectric constant of 1. The plurality of rings, spokes, voids, andcircle including ring layer 306A, spoke 304A, void 308A, and circle 302Aeach have an effective dielectric constant as part of an overalldielectric profile for spoke and ring design 300A. In one example,rings, spokes, and voids have an effective dielectric constant based onthe volumes of the first and second dielectric materials, and circle302A has an effective dielectric constant based on the first dielectricmaterial. In some examples, ring, spokes, and voids have an effectiveconstant based on the volumes of two or more dielectric materials. Inother examples, circle 302A has an effective dielectric constant basedon one or more dielectric materials. In some examples of spoke and ringdesign 300A of FIG. 9A, the effective dielectric constants for thespokes, rings, circle, and voids may have an overall dielectric profilesimilar to a GRIN lens, such as a biconvex lens.

In the example of FIG. 9B, the array of three-dimensional voxels 300Bincludes an enhanced view of rings, spokes, voids, and a circle, such asring layer 306B, spoke 304B, and void 308B. In some examples of the ringand spoke design 300B, the GRIN lens may be constructed with analternating layer of spoke layers and ring layers to reduce itssensitivity to the polarization of an EM wave. Ring layer 306B, spoke304B, and void 308B may consist of a different volume of one or moredielectric materials (e.g., photo-reactive resin and air) structured inthe ring and spoke design 300B. For example, ring layer 306B has thelowest ratio of first dielectric material (e.g., photo-reactive resin)to second dielectric material (e.g., air), as void 308B has the largestvolume at the edge of ring and spoke design 300B. In other examples,each subsequent ring has a higher ratio of the first dielectric materialto the second dielectric material because the volume of the voids getssmaller towards the center of ring and spoke design. That is, in oneexample, ring layer 306B has the lowest ratio of first dielectricmaterial to the second dielectric material.

In some examples of FIG. 9B, the first dielectric material has adielectric constant of 2.8 and the second dielectric material has adielectric constant of 1. The plurality of rings, spokes, and voidsincluding ring layer 306B, spoke 304B, and void 308B each have aneffective dielectric constant as part of an overall dielectric profilefor the ring and spoke design 300B. In one example, rings, spokes, andvoids have an effective dielectric constant based on the volumes of thefirst and second dielectric materials. In some examples, ring, spokes,and voids have an effective constant based on the volumes of two or moredielectric materials. In some examples of the ring and spoke design 300Bof FIG. 9B, the effective dielectric constants for the spokes, rings,circle, and voids may have an overall dielectric profile similar to aGRIN lens, such as a biconvex lens.

FIG. 10 is a diagram illustrating an example of an array of physicalthree-dimensional voxels structured in a spoke and ring design 320. Insome examples of FIG. 10, some reference numerals may be described withrespect to FIGS. 7-9B.

In the example of FIG. 10, the array of three-dimensional voxels of thespoke and ring design 320 includes ring layers, spoke ring layers,voids, and a center, such as ring layer 326, spoke ring layer 324, void328, and center 322. In the example of FIG. 10, the top layer of spokeand ring design 320 is a spoke ring layer, such as spoke ring design 200as described by FIG. 7. In some examples of the spoke and ring design320, as depicted in FIG. 10 the GRIN lens may be constructed with analternating layer of ring layers and spoke layers to reduce itssensitivity to the polarization of an EM wave. In some examples, thespoke and ring design 320 may have a diameter based on a givenwavelength of an electromagnetic wave. In other examples, the spoke andring design 320 may interleave 15 spoke layers with 15 ring layers toachieve a thickness of 7.8 mm, and diameter of 50 mm or approximately 10wavelengths of a 60 GHz wave which has a full wavelength ofapproximately 5 mm.

In one example implementation of 3D GRIN lens 320, ring layer 326, spokering layer 324, and void 328 may each have a different volume of one ormore dielectric materials (e.g., photo-reactive resin and air)structured in the spoke and ring design 320. For example, ring layer 326has the lowest ratio of a first dielectric material (e.g.,photo-reactive resin) to a second dielectric material (e.g., air), asthe voids, such as void 328 has the largest volume of second dielectricmaterial at the edge of the spoke and ring design 320.

In other examples, each ring in ring layer 326 closer to center 322 mayhave a higher ratio of the first dielectric material to the seconddielectric material because the volume of the second dielectric materialin the voids decreases towards center 322. That is, in one example, thering of ring layer 326 closest to center 322 has the highest ratio ofthe first dielectric material to the second dielectric material. In someexamples, each ring of spokes in spoke layer 324 closer to center 322may have a higher ratio of the first dielectric material to the seconddielectric material because the volume of the second dielectric materialin the voids, such as void 328, decreases towards center 332. That is,in one example, the ring of spokes in spokes layer 324 closest to center322 has the highest ratio of the first dielectric material to the seconddielectric material. Moreover, in one example of FIG. 10, center 322 maycomprise one dielectric material, such as the first dielectric material(e.g., photo-reactive resin). In some examples, the spoke and ringdesign 320 comprises a dielectric profile of a biconvex GRIN lens.

FIG. 11 is a diagram illustrating an example of a structure with anarray of physical three-dimensional voxels in a ring and spoke design330. In some examples of FIG. 11, some reference numerals may bedescribed with respect to FIGS. 7-10.

In the example of FIG. 11, the array of three-dimensional voxels of thering and spoke design 330 includes ring layers, spoke layers, voids, anda center, such as ring layer 336, spoke layer 334, void 338, and center332. In the example of FIG. 11, the top layer of the ring and spokedesign 330 is a ring layer, such as ring design 250 as described by FIG.8. In some examples of ring and spoke design 330, as depicted in FIG. 11the GRIN lens may be constructed with an alternating layer of ringlayers and spoke layers to reduce its sensitivity to the polarization ofan EM wave. In some examples, the ring and spoke design 330 may have adiameter based on given wavelength of an electromagnetic wave. In otherexamples, the ring and spoke design 330 may interleave 15 spoke layerswith 15 ring layers to achieve a diameter of 50 mm or approximately 10wavelengths of a 60 GHz wave, which has a full wavelength ofapproximately 5 mm.

In one example implementation of the ring and spoke design 330, ringlayer 336, spoke layer 334, and void 338 may each have a differentvolume of one or more dielectric materials (e.g., photo-reactive resinand/or air) structured in the ring and spoke design 330. For example,ring layer 336 has the lowest ratio of a first dielectric material(e.g., photo-reactive resin) to a second dielectric material (e.g.,air), as the voids, such as void 338 has the largest volume of seconddielectric material at the edge of ring and spoke design 330.

In other examples, each ring in ring layer 336 closer to center 332 mayhave a higher ratio of the first dielectric material to the seconddielectric material because the volume of the second dielectric materialin the voids decreases towards center 332. That is, in one example, thering in ring layer 336 closest to center 332 has the highest ratio ofthe first dielectric material to the second dielectric material. In someexamples, each ring of spokes in spoke layer 334 closer to center 332may have a higher ratio of the first dielectric material to the seconddielectric material because the volume of the dielectric material in thevoids decreases towards center 332. That is, in one example, the ring ofspokes in spokes layer 334 closest to center 332 has the highest ratioof the first dielectric material to the second dielectric material.Moreover, in one example of FIG. 11, center 332 may comprise onedielectric material, such as the first dielectric material (e.g.,photo-reactive resin). In some examples, the ring and spoke design 330comprises a dielectric profile of a biconvex GRIN lens.

FIG. 12 is a graph illustrating an example of the desired density of afirst dielectric material according to the radius of a 3D GRIN lens. Inthe example of FIG. 12, density 402 decreases as represented by line 406from a density of approximately 100% at 0 mm of radius 404 toapproximately 50% at 25 mm of radius 404, as depicted in FIG. 12.Density 402 is a function of the volume of the first and seconddielectric material along radius 404 of a 3D GRIN lens. Radius 404 is afunction of the dimensions of a GRIN lens. Line 406, in one example,represents the approximate dielectric profile of a biconvex lens.

Using equation 1, the index of refraction, n, for a radial graded lenswith a focal length f and a thickness t is calculated and shown in Table1 below with a focal length of 25 mm and a thickness of 7.5 mm. WhereΔn=n_(xo)−n_(x) (n_(xo) and n_(x) are the refractive indexes in positionx_(o) and x respectively), and Δx=x−x_(o).

$\begin{matrix}{{\Delta \; n} = \frac{\sqrt{f^{2} + {\Delta \; x^{2}}} - f}{t}} & (1)\end{matrix}$

TABLE 1

The columns of Table 1 include delta n, n effective, and percent densityversus radius. In the example implementation, Table 1 assumes that thenominal relative dielectric constant of the first dielectric material,such as bulk 3D print material is 2.8. Moreover, Table 1 assumes thatthe nominal relative dielectric constant of the second dielectricmaterial, such as a vacuum, is 0. In other example implementations, thenominal relative dielectric constant of the first dielectric material(e.g., bulk 3D print material) is 2.8 and the nominal relativedielectric constant of the second dielectric material (e.g., air) is 1.The table entries that are highlighted are the dielectric constants thatwere used in the stepped dialectic constant GRIN lens model depicted inFIG. 15, with simulation results shown below. In practice the dielectricconstant does not need to be stepped, but can be varied in a morecontinuous manner.

FIGS. 13A & 13B are graphs illustrating an example of the measured gainpatterns without a GRIN lens and with a GRINS lens as described in FIGS.10 and 11. In the example of FIGS. 13A & 13B, graphs 500 and 502 includethe measured gain patterns 504 and 506.

Measured gain pattern 504 represents a 360° measured gain pattern of 60GHz waves radiated from a flange in a waveguide, such as waveguide 54 asdescribed in FIG. 3, without a GRIN lens to focus the 60 GHz waves.Measured gain pattern 504 is normalized to unity. In some examples, theflange of the waveguide, such as waveguide 52, may have an opening of3.8 mm by 1.9 mm wide. Measured gain pattern 506 represents a 360°measured gain pattern of 60 GHz waves produced by a waveguide, such aswaveguide 52 as described in FIG. 3, with a GRIN lens according to thetechniques described herein to focus the 60 GHz waves. Moreover,measured gain pattern 506 shows the high amplitude, narrow, focused beamradiation pattern resulting from having the GRIN lens according to thetechniques described herein placed in front of the waveguide. In someexamples of FIG. 13A, measured gain pattern 506 may have amplitude thatis 21 times greater than the amplitude of measured gain pattern 504. Insome examples of FIGS. 13A and 13B, measured gain 504 may have a lowamplitude, broad, unfocused beam radiation pattern resulting from nothaving the GRIN lens according to the techniques described herein placedin front of the waveguide. In some examples of FIG. 13B, measured gainpattern 504 may have amplitude of 1.

FIG. 14 is a conceptual diagram 600 illustrating an example of thefocusing effect of a first dielectric material with a single dielectricconstant with a structure of a biconvex lens. In the example of FIG. 14,the conceptual diagram 600 includes waves 604, a GRIN lens 602, andfocused waves 606.

Waves 604 represent the waves passing through GRIN lens 602. GRIN lens602 is represented as a biconvex lens structure, but may not be limitedto this structure. Focused waves 606 represent the focusing effect onwaves 604 after waves 604 pass through a GRIN lens, such as GRIN lens602. In one example implementation, waves 604 may have a frequency of 60GHz. In another example implementation, GRIN lens 602 may have onedielectric material forming the biconvex shape and dielectric profileproviding lens functionality approximating that of a biconvex lens.

FIG. 15 is a conceptual diagram illustrating an example of a steppedGRIN lens 610 including two or more dielectric materials with a steppeddielectric profile and focusing effect similar to a biconvex lens. Inthe example of FIG. 15, stepped GRIN lens 610 includes a plurality oflayers, such as layers 612A, 612B, 614A, 614B, 626A, 626B. In oneexample, the plurality of layers are symmetric across a u-axis toachieve the dielectric profile and focusing effect similar to a biconvexlens. In another example, the plurality of layers includes a pluralityof voxels (not shown). In some examples, each color represents aspecific dielectric constant that correlates with a boxed dielectricconstant as shown and described in Table 1 of FIG. 12.

In one example implementation, each of the symmetric layers, such aslayers 612A, 612B may have a similar ratio of a first dielectricmaterial to a second dielectric material. In another exampleimplementation, each of the symmetric layers, such as layers 612A, 612Bmay have a similar continuously varied ratio of a first dielectricmaterial to a second dielectric material defined by the plurality ofvoxels. In some examples, symmetric layers 612A, 612B may have a similareffective dielectric constant because of the similar ratio of the firstdielectric material to the second dielectric material. In otherexamples, symmetric layers 612A, 612B may have a similar effectivedielectric constant because of the similar volumes of the firstdielectric material to the second dielectric material. In yet otherexamples, symmetric layers 612A, 612B may have a similar effectivedielectric constant because of the similar densities between the firstdielectric material to the second dielectric material.

FIG. 16 is a conceptual diagram 630 illustrating an example of thefocusing effect of two or more dielectric materials forming a steppeddielectric profile according to the techniques disclosed herein. In theexample of FIG. 16, the conceptual diagram 630 includes waves 634, astepped GRIN lens 610 as described in FIG. 15, and focused waves 636.Stepped GRIN lens 610 was simulated, using computer simulationtechnology (CST) software, by directing a 60 GHz plane wave toward thelens. The plane wave originated in the positive u direction and traveledtoward the lens in the negative u direction. The plane wave is parallelto the vw plane. Note that the uvw rectangular coordinate system isanalogous with the xyz rectangular coordinate system.

Waves 634 represent the waves passing through stepped GRIN lens 610.Stepped GRIN lens 610 is depicted as a GRIN lens with flat sides, butmay not be limited to this structure, and may be any structure subjectto the limitations of AM device 24 as described in FIG. 1. Focused waves636 represent the focusing effect on waves 634 after waves 634 passthrough a GRIN lens, such as stepped GRIN lens 610 or GRIN lens 602 asdescribed in FIG. 14.

In one example implementation, waves 634 may have a frequency of 60 GHz.In another example implementation, stepped GRIN lens 610 may have two ormore dielectric materials forming a dielectric profile providing lensfunctionality approximating that of an imaging lens, such as a solidbiconvex lens like GRIN lens 602 of FIG. 14, without the shape of abiconvex lens, as described in FIG. 15. In some examples, focused waves636 may have a similar and/or approximate focusing effect as focusedwaves 606 as described in FIG. 14.

FIG. 17 is a conceptual diagram illustrating an example of the focusingeffect of two or more dielectric materials forming a stepped dielectricprofile according to the techniques disclosed herein. In the example ofFIG. 17, the conceptual diagram 640 includes waves 644, a stepped GRINlens 610, and focused waves 646. Stepped GRIN lens 610 was simulated,using CST software, by directing a 60 GHz plane wave toward the lens.The plane wave originated in the positive u direction and traveledtoward the lens in the negative u direction. The plane wave is parallelto the vw plane. Note that the uvw rectangular coordinate system isanalogous with the xyz rectangular coordinate system.

Waves 644 represent the waves passing through stepped GRIN lens 610.Stepped GRIN lens 610 is depicted in FIG. 17 as a GRIN lens with flatsides, but may not be limited to this structure, and may be anystructure subject to the limitations of AM device 24 as described inFIG. 1. Focused waves 646 represent the focusing effect on waves 644after waves 644 pass through a GRIN lens, such as stepped GRIN lens 610or GRIN lens 602 as described in FIG. 14.

In one example implementation, waves 644 may have a frequency of 60 GHz.In another example implementation, stepped GRIN lens 610 may have two ormore dielectric materials forming a dielectric profile providing lensfunctionality approximating that of an imaging lens, such as a solidbiconvex lens like GRIN lens 602 of FIG. 14, without the shape of abiconvex lens, as described in FIG. 15. In some examples, focused waves646 may have a similar and/or approximate focusing effect as focusedwaves 606 as described in FIG. 14.

FIG. 18 illustrates an example of a non-woven structure 700 with two ormore dielectric materials according to the techniques disclosed herein.In the example of FIG. 18, the non-woven structure includes GRIN lens702. GRIN lens 702 is depicted in FIG. 18 as a GRIN lens with a flatside and comprising a non-woven material.

In one example implementation, GRIN lens 702 may have two or moredielectric materials forming a dielectric profile providing lensfunctionality approximating that of an imaging lens, such as a solidbiconvex lens like GRIN lens 602 of FIG. 14, without the shape of abiconvex lens, as described in FIG. 15. In some examples, GRIN lens 702may be formed by AM device 24 as described by FIG. 1, and AM device 24may generate a random or pseudo-random extrusion path of 3D printedmaterial corresponding to a defined ratio of volumes between two or moredielectric materials. In the example of FIG. 18, an effective dielectricconstant of a GRIN lens 702 is a function of the local print density ofthe extruded material. In some examples, the non-woven structure of GRINlens 702 may include an arrangement of one or more volume elementshaving an arrangement of one or more lines formed by the additivemanufacturing process. In other examples, the volumetric ratio of thefirst dielectric material to the second dielectric material in therespective volume elements is controlled by a line width of the firstdielectric material formed by the additive manufacturing process. Insome examples, the arrangement of one or more volume elements mayinclude an array of randomly extruded paths of at least the firstdielectric material.

FIG. 19 illustrates another example of a non-woven structure 710 withtwo or more dielectric materials according to the techniques disclosedherein. In the example of FIG. 19, the non-woven structure includes GRINlens 712. GRIN lens 712 is depicted in FIG. 19 as a GRIN lens with aplurality of spokes and comprising a non-woven material. In one exampleimplementation, GRIN lens 712 may have two or more dielectric materialsforming a dielectric profile providing lens functionality approximatingthat of an imaging lens, such as a solid biconvex lens like GRIN lens602 of FIG. 14, without the shape of a biconvex lens, as described inFIG. 15. In some examples, GRIN lens 712 may be formed by AM device 24as described by FIG. 1, and AM device 24 may generate a random array ofvoxels corresponding to a defined ratio of volumes between two or moredielectric materials.

FIG. 20 is a flowchart illustrating an example operation 800 of anadditive manufacturing device 24 generating a 3D GRIN lens with two ormore dielectric materials according to the techniques disclosed herein.For purposes of example, FIG. 20 will be described with respect to AMdevice 24 of FIG. 1.

Initially, AM device 24 receives a model that includes data specifying aplurality of layers, at least one layer including an arrangement of oneor more volume elements that includes a first dielectric material and asecond dielectric material (802). For example, AM device 24 may be amanufacturing device having one or more processors, which receives amodel comprising data specifying a plurality of layers, wherein at leastone layer of the plurality of layers comprises an arrangement of one ormore volume elements comprising a first dielectric material and a seconddielectric material, wherein the at least one layer of the plurality oflayers has a dielectric profile that is made up of a plurality ofdifferent effective dielectric constants of the volume elements in thelayer. In some examples, each of the local effective dielectricconstants is a function of a volumetric ratio of the first dielectricmaterial to the second dielectric material in the respective volumeelements, a dielectric constant of the first dielectric material, and adielectric constant of the second dielectric material. After AM device24 receives the model, AM device 24 generates a GRIN lens by an additivemanufacturing process based on the model (804). In some examples, the atleast one layer of the plurality of layers has a dielectric profile thatis made up of a plurality of different effective dielectric constants ofthe volume elements in the layer.

Various examples of the disclosure have been described. These and otherexamples are within the scope of the following claims.

1. A method of forming a gradient index (GRIN) lens for propagating anelectromagnetic wave, the method comprising: receiving, by amanufacturing device having one or more processors, a model comprisingdata specifying a plurality of layers, wherein at least one layer of theplurality of layers comprises an arrangement of one or more volumeelements comprising a first dielectric material and a second dielectricmaterial, wherein the at least one layer of the plurality of layers hasa dielectric profile that is made up of a plurality of differenteffective dielectric constants of the volume elements in the layer; andgenerating, with the manufacturing device by an additive manufacturingprocess, the GRIN lens based on the model.
 2. The method of claim 1,wherein each of the local effective dielectric constants is a functionof a volumetric ratio of the first dielectric material to the seconddielectric material in the respective volume elements, a dielectricconstant of the first dielectric material, and a dielectric constant ofthe second dielectric material.
 3. The method of claim 1, wherein athickness of each of the plurality of layers is smaller than awavelength of the electromagnetic wave.
 4. The method of claim 1,wherein a thickness of each of the plurality of layers is between onetenth and one fifteenth the length of a wavelength of theelectromagnetic wave.
 5. The method of claim 1, wherein the arrangementof one or more volume elements comprises an arrangement of one or morelines formed by the additive manufacturing process. 6-8. (canceled) 9.The method of claim 5, wherein the volumetric ratio of the firstdielectric material to the second dielectric material in the respectivevolume elements is controlled by a line width of the first dielectricmaterial formed by the additive manufacturing process.
 10. The method ofclaim 1, wherein the arrangement of one or more volume elementscomprises an array of randomly extruded paths of at least the firstdielectric material.
 11. (canceled)
 12. The method of claim 1, whereinthe first dielectric material comprises at least one of a firstphoto-reactive resin or a first thermoplastic resin, and wherein thesecond dielectric material comprises at least one of a secondphoto-reactive resin or a second thermoplastic resin.
 13. The method ofclaim 1, wherein the additive manufacturing process comprises athree-dimensional (3D) printing process.
 14. (canceled)
 15. The methodof claim 1, wherein the dielectric profile is selected to enable theGRIN lens to focus the electromagnetic wave. 16-19. (canceled)
 20. Agradient index (GRIN) lens for propagating an electromagnetic wave, thelens comprising: a plurality of layers additively formed to comprise aplurality of volume elements, wherein at least one layer of theplurality of layers comprises an arrangement of the one or more volumeelements, wherein each of the volume elements comprises a firstdielectric material and a second dielectric material, wherein the atleast one layer of the plurality of layers has a dielectric profile thatis made up of a plurality of different effective dielectric constants ofthe volume elements in the layer, and wherein each of the localeffective dielectric constants is a function of a volumetric ratio ofthe first dielectric material to the second dielectric material in therespective volume elements, a dielectric constant of the firstdielectric material, and a dielectric constant of the second dielectricmaterial.
 21. The GRIN lens of claim 20, wherein a thickness of each ofthe plurality of layers is smaller than a wavelength of theelectromagnetic wave.
 22. The GRIN lens of claim 20, wherein a thicknessof each of the plurality of layers is between one tenth and onefifteenth the length of a wavelength of the electromagnetic wave. 23.The GRIN lens of claim 20, wherein the arrangement of one or more volumeelements comprises an arrangement of one or more lines formed by theadditive manufacturing process. 24-26. (canceled)
 27. The GRIN lens ofclaim 23, wherein the volumetric ratio of the first dielectric materialto the second dielectric material in the respective volume elements iscontrolled by a line width of the first dielectric material formed bythe additive manufacturing process.
 28. The GRIN lens of claim 20,wherein the arrangement of one or more volume elements comprises anarray of randomly extruded paths of at least the first dielectricmaterial.
 29. The GRIN lens of claim 20, wherein the first dielectricmaterial comprises at least one of a first photo-reactive resin or afirst thermoplastic resin, and wherein the second dielectric materialcomprises air.
 30. The GRIN lens of claim 20, wherein the firstdielectric material comprises at least one of a first photo-reactiveresin or a first thermoplastic resin, and wherein the second dielectricmaterial comprises at least one of a second photo-reactive resin or asecond thermoplastic resin. 31-32. (canceled)
 33. The GRIN lens of claim20, wherein the dielectric profile is selected to enable the GRIN lensto focus the electromagnetic wave.
 34. The GRIN lens of claim 20,wherein a frequency of the electromagnetic wave is within a millimeterwave band.
 35. (canceled)
 36. The GRIN lens of claim 20, wherein atleast one of the dielectric materials provides a specific porosity forfiltration of at least one of a gas or a liquid.